Don't log in here often but was surprised to see my first ever pocket foil board build in the thread. The carbon one 3rd picture down.
Build went as follows;
Found insulation foam on Swiss building site, relocated 1 block for testing purposes.
Made stencil form using balsa wood.
Pinned stencil to foam and cut out.
Wrapped in biaxial carbon first the another layer of normal carbon.
No vacuum.
Tooooo much epoxy.
Zero board making skills or knowledge.
Turned out the board had pin holes all through it and filled with water. Eventually got cut up to remove the mounting boxes. Those boxes were then put in an old shortened sup board to be used for wind winging.
The following photos are of my 3rd and 4th board (second board ended up in Germany I think).
Build went as follows;
Green EPS closed cell foam from carbon composites UK.
Cut with a Stanley knife.
Layered and epoxy glued.
Layed on a wood form for rocker and concave/convex.
Placed on a table whilst layered glue was still wet, vacuumed to desired shape.
Sanded and shaped.
Biaxial carbon vacuumed base.
Sanded shaped.
Normal carbon vacuumed.
Sanded and shaped.
Then repeated on top/deck.
Once complete I sanded the base to a mirror finish, 1200, 3000, then buffed.
Deck was left with peel ply finish for grip.
I didn't use vacuum bags but a large piece of latex double sided taped to a metal frame, C clamped to a table. Thus making it reusable. The vacuum table system belongs to a Longboard skateboard building business here in Zurich. (Fibretec.ch) if you're in West Aust. You can see their board builds at "livid skate cafe" in Scarborough.
Board with tracks 1.9 kg
Board with nut inserts (snowboard binding inserts) 1.3kg
I add a NSI stick on loop to attach a small yellow float cut from pool noodle just to make seeing the dark board easier.
They float well with my GONG Allvator and Project Cedrus foils.
Boards are now 3 years old and showing signs of wear but no issues.